K D 3 8 8

K D 4 8 8

DIESEL

Safety precautions and notices are described throughout this operation manual

for safe operation. Symbols used in this manual and their meanings are explained

below:

1.1 Warning SymbolsFollowing the precautions described in this manual will enable you to use this

engine with compete satisfaction. Failure to observe any of the rules and

precautions, however, many result in a scalding , injury, fire or engine damage.

Read this manual carefully and be sure you fully understand it before beginning

operations.

These are the warning signs which are used in this manual and the products.

Indicates an imminently hazardous situation which, if

not avoided, WILL result in death or serious injury.

Indicates a potentially hazardous situations which, if not

avoided, COULD result in death or serious injury.

Indicates a potentially hazardous situations which, if not

avoided, MAY result in minor or moderate injury

The descriptions captioned by NOTICE are particularly important cautions

for handing. If you ignore them , the performance of your machine may be

deteriorated, leading to trouble

Make sure to also observe warning indicated on the driven machine and

instructions contained in the operation manual supplied form the driven machine

manufacturer

1.2 Safety Precautions Observe these instructions for your own safety.

1.2.1 Caution

Only the professional and technical person is allowed to run the engine, if not,

the person is subject to cause hurt and mechanical failure easily.

Never operate the engine in the state of fatigue, drunken and medicine.

Insensitive and slowness reaction may result in sudden disaster .

1. FOR YOUR SAFETY

WARNING

NOTE

CAUTION

Please wear the clothes and protection appliance suitable for the task

Note the abnormal situation

When you are operating or maintenance checking, if you find anything abnormal

(noise, violation, smoke, leakage and alarm light), please stop the engine and

report to principle immediately. Don't start engine again until the elimination of the

failure.

1.2.2 Notice for safe operation

1.2.2.1 Burns from Scalding

Never open the radiator filler cap while the engine is hot. Steam and hot water

will splash and scald you seriously. Wait until the radiator cools down after the

engine has stopped, wrap the filler cap with rags then open the cap slowly.

Securely tighten the filler cap of the radiator after checking. Steam can spurt

out during operation, if the cap is tightened loose

1.2.2.2 Good Ventilation for the Battery

Keep the area around the battery well ventilated. Be sure to keep away any fire

source. During operation or charging, hydrogen gas is generated and from the

battery and easy to be ignited.

1.2.2.3 Fire hazard of the fuel

Be sure to use the appropriate diesel fuel. Filling with gasoline or the similar

type by mistake will result in fire.

Be sure to stop the engine before refueling.

If fuel is spilled, wipe off the spillage completely.

Never place oils or other flammable materials near the engine, or it would result

in fire.

1.2.2.4 Exhaust Gas Poisoning

Never block windows, ventilation ports, or other ventilation equipment. Ensure

there is good ventilation during the operation. It is harmful to Inhale the exhaust

gas.

Never operate the engine in a closed room, tunnel, underground room, and

manhole and so on. It is dangerous because exhaust won't exhaust outside.

1.2.2.5 Keep away from moving parts

Be careful not to touch the rotary parts during the running. Keep away the hand,

body and clothes from being caught or scraped by the rotary parts, such as fan

impeller, flywheel, belting wheel or output shaft.

Check if there are tools and clothes on or near the engine to avoid being

caught or hurt.

1.2.2.6 Scalds for the Hot Parts

Don't allow your hand and body and clothes to contact the silencer, exhaust pipe

and engine body during operation or immediately after stopping the engine.

1.2.2.7 Never Operate the Engine under the influence of alcohol

Also, never operate the engine when you are ill or feel unwell because it will

result in unexpected accidents

1.2. 3 Safe notice for inspection

1.2.3.1 Don't contact battery electrolyte.

Pay attention to avoid your eyes or skin from contacting the fluid. The battery

electrolyte is dilute sulfuric acid and would cause burn. Wash it off immediately with

a large amount of fresh water if get any on

1.2.3.2 Fire hazard caused by Electric Short-Circuits

Make sure to turn off the battery switch or disconnect the negative cable before

inspecting the electrical system. Failure to do so could cause short circuit and fires.

1.2.3.3 Keep away from moving parts

Stop the engine before servicing the engine. If inspect the engine while running,

never bring your hand, body or clothing contact or near rotating parts, otherwise

you might get injured.

1.2.3.4 Prevent Scalding from the Hot Oil and Water

If lube oil must be drained from the engine while it is still hot, be sure not to let

the oil splash, causing to scald.

Wait until the temperature goes down before draining the coolant. Hot water may

splash, resulting in scald.

1.2.3.5 Beware of dirt in air blowing

Wear protective equipment such as goggles to protect your eyes when blows

compressed air. Flying dust or debris may hurt eyes.

Modification not authorized is forbidden

Do not release the control the high-speed limiting screw and oil level limiting bolt,

otherwise the engine life will be shortened. Any rebuilding or disassembling of the

engine will decrease safety, even causing a serious accident. If necessary, contact

your local Kipor agents for Replace the genuine parts or technical support.

Disposal of waste materials

Gather waste oil or drainage in a container. Never dispose of waste oil or drainage

to outdoors, or into a sewer, river, or the sea.

Dispose of waste materials safely by observing relevant regulations and laws. Ask a

specialized waste recovery company to collect and dispose the waste materials.

WARNING

NOTE

2. PRODUCT OVERVIEW2.2 PRODUCT INSTRUCTION:

Type

Cylinder no-Bore Cycle (mm)

Piston Displacement (L)

Compression ratio

Fire order

Inlet ways

Fuel consumption (g/kw.h)

Lubrication system

Cooling system

Stating system

Location of output terminal

Rotation speed of output terminal

Starting motor capacity

DC charging generator capacity

Accumulator capacity

Lube oil capacity (L)

Cooling water capacity

Overall dimension (L W H)

Net weight (kg)

KD488ZKD388 KD388Z KD488

3 88 90

1.642

4 88 90

2.190

17.518.2 17.5 18.2

1 3 2 (from flywheel terminal) 1 3 4 2 (from flywheel terminal)

12.3(16.7)/1500

14.8(20.1)/1800

20(27.2)/2200

24(32.6)/2600

27(36.7)/3000

31.5(42.8)/3600

14.5(19.7)/1500

17.5(23.8)/1800

24(32.6)/2200

28.8(39.2)/2600

32.4(44)3000

37.6(51)/3600

16.4(22.3)/1500

19.7(26.8)/1800

26.7(36.3)/2200

32(43.5)/2600

36(49)3000

41.8(56.8)/3600

19.5(26.5)1500

23.5(32)1800

32(43.5)/2200

38.4(52.2)/2600

43.2(58.5)/3000

50(68)/3600

1500rpm, 230g/kw h 3000rpm, 258g/kw h

Composite Pressure and splash

Forced liquid cooling closed type cycle

Starting motor

Flywheel terminal of horizontal axis

Counterclockwise (face to flywheel)

12V 1.4kw

12V 15A

12V 80Ah

6.9

4.6

(610.5 449.5 641.5)mm

8.5

5.9

(704.5 449.5 641.5)mm

205170 175 200

Note: when the speed 2000r/min and the max. torque=115 percent of the rated power,

the speed under the max torque is 70~75 percent of the rated speed

This engine type is in-line, vertical, 4-stroke, water-cooled cylinder line, direct-

injection combustion chamber, 4-cylinder diesel. And these products consist of

three types, including charged, exhaust turbocharged and intercooling.

This engine is of easy frame and easy to dismantle. The overall dimension is

small and the weight is light. Its performance is wonderful, which can meet

different customer's requirement, namely, generator sets, architecture machine,

transportation engine, vessel dynamo, combine harvester and agricultural

mechanism.

2.1 Frame feature2.1.1 The screw intake pipe is adopted, which makes the intake air go around the

axes. The mist oil grain and the compression air become comparatively ideal

flammable bland gas

2.1.2 For the top land designed as foursquare arc shape, W rotator in the bottom,

excellent match with the vortex helix inlet pipe in the cylinder. High combustion

efficiency as the fuel mixes with the air contently. With little fuel it can provide

huge power.

2.1.3 Low inertia pin injection, which has a 10 slope with the cylinder axes .the

injection head is 1.5mm 4mm away from the cylinder center. The injection

diameter is 0.18MM .There are four bind of oil fog falling on the side cliff of ù

combustion chamber on the head of piston, which can well mix the oil fog and the

air.

2.1.4 Adopt VE type proportioning pump, provide a smart cube appearance; the

oil injection pressure of the long cellular type (4 bore) oil injector is 16.5Mpa, and

the location of the fuel falling is in the exact position of the combustion chamber,

thus provide the high efficiency of combusting. For the charged type, adopt the 5-

bore oil injector with the oil injection pressure 20Mpa.

2.1.5 Install board heater in the intake flange to warm up the gas in the cylinder.

The use of glow/heater plug greatly improves the diesel starting efficiency of

small bore direct injection combustion chamber.

2.1.6 With the inlayed thin wall (1mm thick) chrome plated (0.10.12mm net shape

chrome) wear resistance, thermo stability and resistance to corrosion of the

cylinder improved.

2.1.7 For the lubricating system, it adopts forced lubrication with trochoid pump.

The oil pump is rotor type with large oil capacity, small pulse, stable oil supply.

2.1.8 For the cooling system the water temperature is kept at 80 --95 by the

thermostat.

Item

Model

Specification

Rated power/speed

Kw(ps)/rpm

In-line, water-cooled, 4-stroke, directed injection, engine

Nature inspiration Supercharge-middle cooling Nature inspiration Supercharge-middle cooling

2.3 Figure Fixing Drawing and Parts Name

Re

spria

tor fu

bb

er h

ose

Air h

ea

ter

Fu

el filte

r

En

gin

e b

od

y

Flyw

he

el

casin

g

Flyw

he

el

Co

nsta

nt te

mp

era

ture

reg

ula

tor

Fa

n b

lad

e

Co

ola

nt p

um

p

Oil fille

r

Sp

ee

d se

nso

r

VE

Fu

el in

jectio

n p

um

p

Oil filte

r

Oil su

mp

Dra

in o

il rub

be

r pip

e

Portrait view of KD388Portrait view of KD388

Co

nsta

nt te

mp

era

ture

reg

ula

tor

Fa

n b

lad

e

Co

ola

nt p

um

p

Oil fille

r

Sp

ee

d se

nso

r

VE

Fu

el in

jectio

n p

um

p

Oil filte

r

Oil su

mp

Dra

in o

il rub

be

r pip

e

Re

spria

tor fu

bb

er h

ose

Air h

ea

ter

Fu

el filte

r

En

gin

e b

od

y

Flyw

he

el

casin

g

Flyw

he

el

Geer wheel view of KD388/488 Diesel engine

Flywheel view of KD388&488 diesel engine

Fuel injectionInlet rubber hose

Air heater

Fuel filter

Inlet pipe

Fuel injection pump cover board

Oil sump

CrankshaftBelt pulley

Oil sump washer

Oil sump

Hose of draining oil

Cylinder coverand respirator

Exhaust pipe

Hot water outlet

Charging generator

Fan cushion

V belt

Speed sensor

Starting motor

Fuel injection

Injection pump

(equispaced)

2.4 Functions of Major Parts 2.5 Main Adjusting Data Table:

Removes dirt and water from fuel oil, protect the work dependability

and life of the fuel injection pump & fuel injection. Periodic

replacement of filter paper element is necessary before it is clogged

with dirt. Replace the whole cartridge assembly for renewal.

Proportioning pump of VE type. Installed oil transfer pump on outer of

pump, and transfer the cleaned fuel to inner of pump. Doctorbar type

oil transfer pump pressure of pump inner, single plunger type oil pump

pressure oil through delivery valve, high pressure oil pipe, Fuel

injection spray fuel to combustion chamber with a high pressure.

Solenoid valve will chopping, (stop the engine)

Open pinhole under the high pressure fuel function, and spray ties of

fog shape fuel to combustion chamber. Non-supercharge has four

pray nozzles, injection pressure is 20Mpa Supercharge has five pray

nozzles. Injection pressure is 22Mpa.

First admission produce high speed rotation motion under cylinder

suction, remove the dirt from air, air enters cylinder after cleaning

through filter paper element. Protect cylinder liner, piston, piston ring,

valve sealing cone from wearing, and control noise of admission.

Periodic inspection (cleaning or replacement) of the filter paper

element is necessary before it is clogged with dust.

Remove fine metal debris and carbon in the lube oil. Protect axle

journal, Bush, lining from wearing, Periodic replacement of filter paper

element is necessary before it is clogged. Replace it by cartridge

assembly.

Cooling fluid cycles between diesel engine and radiator, dissipate

diesel engine heat from radiator. centrifugal type pump force cooling

fluid to cycle, fan impeller which installed in the axial terminal blows air

for cooling radiator. Thermostat keep the Cooling fluid temperature

between 80?and 95?. There are two valves on the radiator cap:

reducing valve and vacuum valve, they can adjust the internal

pressure of radiator.

Dc motor for starting diesel engine. When the power is turned on , the

pinion gear engages with the ring gear of flywheel to start the engine.

AC generator to charge to the battery through adjust pressure and

commutation while the engine is in operation.

8. Alternator:

1. Fuel filter:

2. Fuel injection

pump:

3. Fuel injection:

4. Air cleaner:

5. Lube oil filter:

6. Cooling water

system (Radiator,

pump, Fan,

thermostat)

7. Starting motor:

Specification

Item

Normal value Limit value

Non-compression space height inside the cylinder mm

Advance angle of fuel supply

Injection pressure Mpa

Valve clearance mm (cold state)

Air valve sub-quality product mm

Nozzle overhang mm

Belt tension mm

Lube pressure Mpa

Lube oil temperature

Drained water temperature

Valve close and open phase

Exhaust temperature

Max. rise distance of inlet/exhaust valve mm

0.8~1.0

Before upper dead point16 1

20 0.5 supercharge 22 0.5

Open at BTDC 10 close at ABDC 45

Open at BBDC 56 , close at ATDC12

8.9

0.10~0.15

0.5 0.10

2.2~2.3

press the belt down 8~12mm with100N pressure

0.25~0.5

110

95

between1500rpm and 2200rpm 520Above 2600rpm 580

Intake valve

Exhaust valve

2.6 Tightening Torque of Main Bolts and Nuts:

Cylinder cover bolt

Main bearing bolt

Connecting rod bolt

Flywheel bolt

Crankshaft pulley bolt

Other bolts: mechanical property is 8.8 grade, tightening torque N.mJapanese

bolt TT

Joint bolt

M10 1.25 98

M12 1.5 73

M9 43

M10 1.25 32

M14 1.5 30

M6

M8

M10

M12

M14

M16

M18

M20

M8

M10

M12

M14

M16

80 5

120 5

60 5

70 5

180 10

8~12

18~26

45~60

80~100

130~150

180~210

240~270

350~400

13~16

20~28

25~32

38~45

48~55

Item

ValueRemark

Tightening torque(N.m)

Threadspecification

Note:

1. If the bolts screw into the aluminum alloy part, the tightening torque should be

about 80% of the small value at left column.

2. If the performance rate is 5.6 grade, the tightening torque should be about 60%

of the small value at left column.

2.7 Operation control system

2.7.1 Starting switchthStarting switch is a kind of 4 grade switch with heat and automatic reset function.

Insert the key into the switch hole and screw it, which enables the starting switch to choose the position.OFF If the key is staying at this position, it means that the engine is stopped, and the key can be released or inserted since all the current is cut off at this position.ON If Current goes through the meter and inspect instrument (alarm system) when the key is on ON position.START Turn the key to the START position and the starter motor will start the engine. Release the key and it will be return to ON position automatically.HEAT When the key is staying at this position, the current will go through the air heater, and the inlet air of the cylinder is heated, resulting the rising of the temperature. Release the key and it will return to OFF automatically.2.7.2 Air-heater (cold starting aid device)

The air-heater is installed in the flange of the inlet pipe to provide an easy starting of the engine, and its working principle goes as following: If the engine is started in a low temperature, switch the current on the air-heater, and the electrical heated platen becomes heater and heater, resulting in the heat of the inlet air.

Turn the key to HEAT position, and the current will go through the air-heater, meanwhile, the heat indicating lamp is on, indicating the beginning of heating. The lamp will go off in about 15 seconds, indicating the finish of heating.

Turn the key clockwise quickly to the START position immediately after the lamp is off, and the pinion of electrical starter will jump out to joggle with the ring gear of flywheel, thus the engine is started.2.7.3 STOPPING-ENGINE DEVICE

If the key is turned to OFF during normal running of the engine, the fuel shut-off electromagnet on the fuel injection pump will actuate to cut off the fuel supply of the fuel injection pump, and thus the fuel injection is stopped, resulting a quick stop of the engine.2.7.4 Speeder: Mechanical centrifugal speeder /all speed governor

Control the engine speed via the speed control lever: Move the control lever upward to raise the speed, or downward to decrease it.

If there is a necessary to operate the speed control lever in a remote place, a remote control device can be attached, and the lever can be controlled by a micro motor.

Never loose the high speed or low speed limit switch because the steady speed of the engine at its maximum and minimum state has been strictly restricted.2.7.5 Alarm lampThese lamps are used to monitor abnormal states during the engine running.2.7.5.1 CHARGE ALARM LAMPThe light will be on when turn on the starting switch, it will be off when the engine is running properly, which means the light is off when battery is charging normally; if not, the battery might be abnormal, and at this moment, please check the cause of the abnormal charging of the engine.

3. Before operation

Environment temperature

-5 or higher

-15 or higher

-25 or higher

GB/T252

-10

-20

-30

JISK2204

2

ASTMD975

Level 2-D

3 Level 1-D

Please check the fan, and check the driving-purpose V belt of the charging generator to see whether it is loosen or destroyed, check the battery liquid level and the electricity leakage etc.

If the light is off when turning on the starting switch, please check the electric joint connection and to see whether it is loosen or fall off. Also please check the concerned bulb, sensor and battery.2.7.5.2 Heat alarm lamp

Start the engine and the heat alarm light will be on for about 15seconds, it will be off after finishing warm up.2.7.5.3 Lube oil low pressure alarm

Turn on the starting switch to start the engine, the low-pressure alarm lamp will be on, and the light will be off when there is normal oil pressure in the oil lines.

2The light will be on if the oil pressure lower to 49Kpa(0.5kgf/cm ) during the normal running of the engine, and as soon as the oil pressure reaches 49Kpa the engine will stop running.

The oil pressure must be above 0.5Mpa, and if the oil pressure is between 20.25Mpa 2.5kgf/cm and 0.5Mpa, a risk running of the engine would be occur,

and the engine cannot run until the pressure is above 49Kpa even at an idle running.

The low oil pressure will result destroy of the cylinder, and it is much easier for the exhaust gas turbocharger to be burnt out.2.7.5.4 Water temperature alarm system.

The light is off when the engine is working normally, ,the temperature of coolant should be between 80 and 95 .

The light will be on and the engine will stop working to protect itself once the coolant temperature is above 95 and reach 110 .

After the engine stopped working, please check the coolant capacity, fan, cooling water pump and driving-purpose V-belt to see if they are loose or broken. Besides, please check the pollution of radiator and fan.

High altitude, high temperature and overload are much easier to result coolant temperature rising, lamp lighting and engine stopping to protect engine itself. 2.7.5.5 Alarm lamp of low intake pressure.

The light will be off when the engine is working normally, and if the air cleaner element is clogged by dirt, the intake resistance will increase, resulting the intake air pressure decrease, while the decrease of the intake pressure comes to an limit the light will be on to alarm.

Stop the engine if the light is on, and clean the air cleaner and its element component, replace its dirty air cleaner element.

2.8 Storage of operation manualKeep the operation manual well for future use.Read the manual carefully for right operation, maintenance and maintain in order

to avoid personnel damage and malfunction to serve you better.

Article 1 to 6 is the preparation procedure for an engine start

3.1 Preparation for the fuel, lube oil and coolant

3.1.1 Fuel

Please use the recommended fuel, otherwise the

engine cannot be operated properly, or there will be

trouble of spare parts.

3.1.1.1 Choices of fuel

Choices of fuel

Complying with int'l standards

ISO8217DMA

ASTMD975 level No.: 1-D or 2 D / ASTMD975

GB/T252-1994 light diesel 0# for summer use, -10#, -20#, -30# for winter use

Diesel is classified by its solidifying point. Some diesel is sluggish in flow under

low temperature. Please choose the proper fuel according to environment

temperature

NOTE

Fuel type

3.1.1.2The use of the fuel

Fuel should be kept in clean cans

Fuel should be kept in clean cans without access to rain. The engine will not

run properly if the fuel is mixed with water or filthy stuff

Keep still the fuel cases for 24 hours until the water and filthy material sink

down on the bottom of the can, and then extract the clean fuel above with a fuel

pump.

3.1.2 Lubricant Oil

In case incorrect oil used, the components in the

Engine might possibly clipped and abraded resulting in

shortening life cycle of the engine.

NOTE

The electrolyte is sulfuric acid. Please don't let the

electrolyte spatter on your eyes, skin and coat to avoid

serious hurt.

If the electrolyte's liquid level is on the "LOWER

LEVEL" marks, please don't use the battery again,

Otherwise, it will cause aging inside the battery, shorten

the use lifetime of the battery and even the battery will

explode.

3.1.4.1Checking the electrolyte's liquid level

Please remove the BATTERY cap and

check the electrolyte's liquid level. The

electrolyte must keep above the middle of

the upper and lower level marks. If below

the middle, please add electrolyte.

3.1.4.2 Checking the electrolyte's proportion

Please refer to the following table of the

mutual connection among the electrolyte

temperature, proportion and recharging rate.

When the remaining bulk is below 75% and

the electrolyte's proportion is between 1.23

and 1.24, please charge the battery.

Reference table of electrolyte temperature, proportion and charging rate%

3.1.4.3 The positive terminal must not be connected to the negative terminal

when checking circuitry Otherwise, it will break the diode on alternator

3.1.4.4 Open the battery cap to let the gas come out during charging.

3.1.4.5 Stop charging the battery for a moment to cool the battery liquid when it is

overheated (above 45 ),then go on after the battery is cooled down.

-15

30

-20

35

-25

40

100

90

80

75

20

1.28

1.26

1.24

1.23

0

1.29

1.27

1.25

1.24

-10

1.30

1.28

1.26

1.25

3.1.2.1 The specification the OilCD Level classified under APIChoosing the correct mucosity oil according to surrounding temperature.

3.1.2.2 the use of the Lubricant OilStock & Using the Oil properly, Avoiding dirt or dust

falling into the oil. Cleaning the Filling-Jaws area while filling the Oil.

In order to avoid impacts of the oil character, Please do not use mixed oil with different specification.

3.1.3 Cooling waterThe misapplication of cooling water may cause radiator, housing unit and cylinder

begrimed and then affect the cooling.More attentions should be taken in cold area because the frozen cooling water

may damage such parts as radiator, housing unit and cylinder cover.3.1.3.1 Cooling waterUsing soft water (from tap water or rain water), and add durable LLC to avoid rust and freezing.3.1.3.2 LLCTo select good-quality durable LLC can avoid rust, and then the antirust is not necessary. The useful-life of cooling water is one year and it should be replaced once a year.3.1.3.3 The ratio of the LLC in the soft water should between 30% and 55%. In standard area (-15 above), it should be 30%; and in cold area ( -35 above), 50%.

Su

rrou

nd

ing

Tem

pe

ratu

re

10W-30 OR 15W-40 oil is applicable

among whole year for general area.

NOTE

Ratio%

The lowest environment temperature

3.1.3.4 The ratio should be moderate: If the ratio of LLC is too low, it is difficult to avoid freezing and rust; on the contrary, if too high, it will also have a harmful effect on cooling the engine. Please keep to the instructions about the ratio made by manufacturer.3.1.4 Battery Operation

Charge the battery in a good ventilated place which is far from fire. The battery may produce flammable gas. If handle it by mistaken, it will cause explode;

The positive terminal must not be connected to the negative terminal when checking circuitry or connecting with cable. Otherwise, it will cause spark to serious hurt and find hazard.

DANGER

Charging rate%

Electrolyte temperature

Proportion

3.1.4.6 Stop charging the battery immediately once the battery is fully charged to avoid

overheated of battery

electrolyte liquid level decreased

abnormal of battery

3.2 fuel supply

3.2.1Filling fuel

Fill the clean fuel without water and other dust to 90% of the fuel tank volumeBe careful when filling the fuel, and make sure not to overflow. Remove the air in the fuel system to assure the normal fuel supply.

3.2.2Compensate the fuel in the fuel system

* The air in the fuel system must be eliminated, otherwise the fuel cannot be fed to the fuel injection pump.

* Since the engine features automatically air bleeding system, please eliminate the air in the fuel system complied to the following steps.

Check the fuel level in the fuel tank. Add the fuel if insufficient.

Turn on the fuel switch on the fuel tank.

Turn the ignition switch to the "ON" position, then the fuel will be supplied by the injection pump. If fuel filter is full of fuel, without gap and air bubble, the engine will be started.

Avoid the fuel catching fire Be sure to fill fuel with the same style, any mistake

may cause fire Be sure to stop the engine before filling Please clean the overflow fuel if necessary. Don't put engine close to any flammables and fuel

otherwise, it may cause fire

3.3 Supplying the Lub Oil

The oil level should be moderate. If the oil is insufficient, bearings and pistons are easily damaged.

If the oil level is too high, the oil consumption will also be high, which will cause carbon accumulation and damage of nozzle and piston.

Supply the oil to the specified level as following procedure:3.3.1 Place the engine on a level position.3.3.2 Remove the cap of the oil filler port on the gear case cover.3.3.3 Add 6.9L specified oil to the 3-cylinder engine and 8.5L specified oil to the 4-cylinder engine.3.3.4 Check the oil level with dipstick (level gauge). Oil should be filled to the upper limit on the dipstick.3.3.5 Manually tigten the cap of the oil filler port.3.3.6 Wait for about 10 minutes after starting the engine, and then stop it. Check the oil level with dipstick. It should be near the upper level.

3.4 Supplying the Cooling Water

Never open the radiator cap while the engine is hot, otherwise the hot water or

steam may spurt out and cause scalding. Remove the radiator cap slowly with a rag piece after the radiator cools down.

Tighten the radiator cap after check on the cooling water capacity. If the cap is

not secure, the steam or hot water may spurt out during operation to cause scalding.*Supply the cool ing water into the radiator and the sub-tank.3.4.1 Remove the radiator cap. Press down the cap and turn it counterclockwise to remove it.3.4.2 Pour the cooling water gently into the port, taking care not to cause bubbling until it overflows. Cooling water capacity is 4.6L3.4.3 Eliminate the air in the cooling system while pour the water into the filler port. And the air should be exhausted from the top position of the outlet to avoid air-restriction.3.4.4 After supplying the cooling water, tighten the radiator cap. First the hook inside the cap should be aimed at the gap on the water filling hole, then turn the cap clockwise by 1/3 circle.3.4.5 Full filling water into the surplus water tank, then tighten the water filling cap.3.4.6 Check the rubber cooling water hose for disconnection, looseness or damage of joint and other faults. If there is poor seal of the cooling water pipe, the cooling water may be consumed too much.3.5 Starting£ N̈o-load£©Run the engine at low and no loaded speed while starting the engine for the first time or after a long-time storage, to circulate the lube oil sufficiently to each part. After a long-time storage, the lube oil may glue the moving parts of the engine. Operating the engine under such a state may cause seizure of rotating parts.3.5.1 Disconnect the switch of power output to keep the diesel engine at idle.3.5.2 Set the control lever (accelerator facilities) at Low position.

Beware of scalding

DANGER

DANGER

NOTE

4. Operation3.5.3 Put the key into the starting switch, and then turn the key to START to start

the engine.

3.5.4 Run the engine for about 5 minutes at the low speed position to check if

there is abnormal sound. Inspect the leak of air, water, fuel & oil.

3.5.5 Turn the key to the OFF position to stop the engine.

3.6Checking the Lube Oil and Cooling Water

When lube or cooling water is supplied for the first time or replaced, run the

engine for about 5 minutes, and then stop engine to check the cooling water and

lube level again. Lube oil will be supplied to each part during running in so that

the oil level at the oil pan will go down apparently. Then refill oil of specified level.

At the same time, refill the cooling water to full as cooling water is consumed

much.

This section describes the preparative procedures for starting and stopping the engine, adjusting the speed before preparing to keep the engine in storage for a long time.

Never drink before operation.

It is not proper to operate when the operator is sick or under the influence of alcohol.

Poisonous exhaust gas

Do not block the hose, intakes, windows and doors for ventilation. There should be good ventilation while the engines is running for exhaust is toxic.

Avoid operation in a closed room, tunnel for exhaust gas cannot get out.

Keep away from rotating parts

Keep your hands, body and clothes sufficiently away from the rotating parts such as cooling fan, V-belt, pulley, etc. during operation. Severe injury will happen if trapped by these rotating parts.

Do not operate the machine when any of its protective covers are removed.Make sure there is no maintaining tools and clothes remained on the machine

before starting the engine.

Beware of scalding from touching the hot parts of engine

Do not touch the muffler, exhaust manifold and engine body during operation or immediately after stopping, otherwise scalding may occur.4.1 Daily Check before OperationBe sure to check the following points before starting the engine each day4.1.1Visually inspect the environment around the engine.

Oil leaks from the lubrication system.Fuel leaks from the fuel system.Water leaks from the cooling system.Parts are damaged.

WARNING

WARNING

DANGER

NOTE

4.1.2Check and add fuel

Check the remained fuel level in the fuel tank and add the recommended fuel as

necessary.

4.1.3Check and add oil

Check the oil level with oil dipstick. If the remnant oil level is too low, add the

specified oil to the upper limit level, inspecting the level to avoid spilling.

4.1.4Check and add cooling water

Check the cooling water level in the radiator and sub-tank after the engine is

cooled down. If the level is too low, add the soft water properly. In daily inspection,

just add cooling water into the sub-tank. If the cooling water level is lower than the

limit, then check the water level in the radiator.

4.1.5Check the agility of governor lever

The governor lever should be operated lightly. If it is hard to manipulate, add oil to

the governor cable joints and pivots. And if there is a dislocation or excessive

clearance between the governor and the control level, adjust it to normal state.

4.1.6Check alarm system

Check all the alarm systems to ensure the alarm system would function normally.

If the alarm system lost its function, it will result in a serious fault.

4.2Starting

4.2.1Start the engine as shown below:

4.2.1.1 Release all clutches or turn the starting switch to OFF position to cut off

the driven load.

4.2.1.2 Open the fuel tank switch.

4.2.1.3 Turn on the battery switch.

4.2.1.4 Insert the key into the starting switch.

4.2.1.5 Turn the key to ON position. Check whether all the alarm system are

normal or not.

4.2.1.6 Set the governor (control lever) at the LOW position.

4.2.1.7 Turn the key to the START position to start the engine. Once the engine

starts, release the key right away. And the key automatically returns to ON

position.

Operate the start switch within 15seconds, otherwise

it will overheat the starter motor.

There should be 15 seconds interval for starting the

engine again.

Starter motor may only drive the flywheel gear to

rotate, but flywheel gear cannot drive the starter motor

to rotate. Otherwise, starter motor will be damaged. So,

once engine is started, disconnect the start gear from

the flywheel gear immediately.

4.2.2Start the engine at low ambient temperatureIf the engine is hard to start in cold weather (approx. 0? or below), use the glow plug for easier start.Follow steps 4.2.1.1to 4.2.1.6 as above, and then follow the steps as below:4.2.2.1 Turn the key from OFF to HEAT, and stay there for about 15 seconds until the glow plug finish preheating process. 4.2.2.2 Turn the key to the START position. After the engine starts, release the key at once. And the key automatically returns to ON position.4.2.3 Restart after failureIf the engine fails to start, wait about 30s to reach the normal battery voltage level, and then turn the switch key to START. If the engine cannot start after several attempts, eliminate the troubles and restart the engine.4.2.4Check and operation after startingAfter the engine starts, run it at the idle speed and check the following items

Alarm lamps and instruments no display of 6 alarm lamps indicates normal

state. Water leak, gas leak and oil leak from engine.

Color of exhaust gas.

Vibration or noise of engine.

. Running

4.3.1Run the engine at a low speed without any load for about 5 minutes to lubricate all the moving parts of the engine, but without long time idle running.4.3.2Increase its speed while the engine is applying for loading and check for the rotating sate such as color of exhaust gas, vibration and noise of the engine.4.3.3Adjust the engine speed by operating the governor lever (control lever) of the accelerator. And engine speed regulation is realized by adjusting the accelerating spring. If the spring increases, as well as fuel supply and engine speed will increase. If the spring decreases, the result will be opposite. 4.3.4Move the governor lever in the accelerator slowly. Avoid accelerating or decelerating the engine fast. It benefits the engine life by increasing the load step by step.

High-speed operation or sudden load without preheating process may result in engine seizure.

NOTE

Do not accelerate or overload the engine abruptly at the

first 50 hours when running a new one.

4.4The notes items of date running

Following below points while inspecting the running state of engine

4.4.1 Exhaust and smoke

If there is much smoke, you should stop the engine. The smoke is the symbol of

the overload or broken. That will shorten the life of the engine. You should avoid it.

4.4.2Abnormal noise or shock

According to the structure of the enegine it will produce resonance at rated

speed the resonance will result in shock and abnormal noise, don't run the

engine at the rotation speed, otherwise the enegine will be damaged.

4.4.3Alarm lamp

If the alarm lamp is light, just cut the power output switch, remove the load, then

reduce the rotation speed, and stop the engine and check it.

4.4.4 Gas leakage, fuel leakage, water leakage and the bolt loose

Check the external parts, be sure that the enegine is no leakage, no loosen bolt.

4.4.5The oil level is too low.

You should check the oil level of oil sump. And add the oil before it drops to the

lowest limit

4.4.6The fuel level of the fuel tank is too low

Check the fuel level of the fuel tank, and add the oil before it drops to the lowest

limit.

4.5 Stop the engine

Stop the engine as following.

4.5.1 Cut off the clutch or load switch to cut off the outside load.

4.5.2 Reduce the speed to the idle speed gradually, running about 5 minutes,

make the temperature of the heated parts lower.

4.5.3 Turn the start key to the "off" position, the engine crankshaft stop rotating.

Take off the key and put it in a safety place.

4.5.4 Turn off the battery switch.

4.5.5 Turn off the switch of the fuel tank

If the starting switch is on "off" position, but the engine is not stopped, you should

turn off the switch of fuel tank, cut off the fuel supply, the engine will stop quickly.

When the engine is running, do not cut off the switch or make a short circuit. Otherwise it will produce strong spark. Abnormal electric surge will result in system fault.

After running, do not stop urgently. Or it will make the

engine temperature zoom, it easy cause adhibit the

cylinder, burn the crankshaft, damage the engine.

4.6 Notice for the long-time storage

If you want to store the engine for long time, please pay attention to the following

points.

4.6.1 The draining of the cooling water: If there is no antifreeze in the cooling

water, make sure drain the cooling water completely. To prevent frost crack the

engine, cylinder cover, radiator, oil radiator etc,.in the cold winter.

Screw out the cover of the radiator.

Open the drain piston or the rubber tube at the bottom of the water tank.

Screw off the drain piston at the bottom of the water tank.

After drain out the cooling water, reinstall every part.

4.6.2 Clean outer parts, oil draining, oiling

Clean the dust and oil dirty on the case of the engine.

To prevent the condensation, you should drain the fuel completely or top up the

fuel tank.

Add lubricant oil to the supporting and connecting point of the timing system.

4.6.3 Waterproof and dustproof

Cover the whole diesel unit with sealed plastic jacket, prevent for the water and

the dust.

Store the engine in a ventilated place, far away from the moist and dusty place.

4.6.4 Measures for the battery discharge itself.

Cut off the unit's switch or ground wire (connect the cathode to the ground)

Charge for the unit once a month, equalize the unit discharge itself.

4.6.5 Check the unit after the long-time storage

If you want to start the long-time storage engine, you should perform the

preparative procedure "before the operation" on chapter 3.

Prevent hurted when draining the hot water. Drain hot

water until temperature is lower. The vapour or hot

water will scald you.

NOTE

NOTE

NOTE

NOTE

5. Maintenance Check Replace Consulting

Adjust the clearance between the intake and exhaust valve

System

Fuel

p.d. 50h 250h 500h 1000h 2000h

first

clean

first anon

anon

Due to the bad condition and the extension work time, the capability of the engine

will become worsen. Such as: increase the consumption of the fuel and oil, and

increase the harmful matter of the exhaust, increase the vibration and noise, and

then shorten the life of the engine. Reinforce the maintenance, daily and terminal

inspection, you can keep the unit's efficiency and prevent the fault.

5.1CheckDaily check and terminal check

Daily check: You should do the daily check before starting the engine every day,

the details have been mentioned in first section of chapter 4, and you should

perform it as a regulation.

Terminal check: Advise you make a running diary, note every day's running and

checking result, add up the unit's work time, make terminal check and

maintenance according to this manual.

Terminal check include: 50h 250h 500h 1000h 2000h(h for hour)

5.2Items for terminal checkThe following list include items and time interval of the terminal check. According

to the engine's use, load condition, fuel and lubricant's quality, and other condition,

the time interval of the terminal check can ahead or delay.

Maintenance

The abrasion of the intake and exhaust sealed belt

Idle speed adjusting

Clean and Replace the element of the air cleaner

Check the warning system

Check the electrolyte level and charge for battery

Check items

Check the fuel leakage

Drain water in the fuel tank

Check the oil level and add

Check the leakage

Replace the lubricant

Replace the filter element

Clean the radiator's element

Replace the cooling water

Operate the speed regulator

Check and supply the fuel tank level

Replace the diesel filter element

Check and add the cooling water

Wash and maintain the cooling system

Replace the fuel and cooling water pipeRubber pipe

Air intake system

Operating

system

Lubricant

Cooling

water

Electrical

equipment

Cylinder

cover

Injector and

injection

pump

Check and adjust for injector pressure

Check and adjust for injector timing

5.3 Procedure for terminal check5.3.1 The first 50 running hours: because the engine just start running, the inside

running parts abration each other, the lubricant will be polluted soon. You should

replace the lubricant and oil filter element. It is easier and quicker to drain the

lubricant, when the engine is still hot.

When drain the hot oil, be care of scalded. Do not make

the hot oil splash to you

5.3.1.1Drain the lubricanta. Prepare a pot to keep the oil.B.Loose the screw with a spanner, start to drain the oil.C.After drain out the oil, be sure to tighten the screw,

5.3.1.2 Replace the oil filter elementScrew off the filter element widdershins with a spanner.

Clean the filter seat.

Install a new element, wipe a thin flat of lubricant in the sealed gasket, tighten it

by clockwise, then use the spanner to screw down 3/4 circle. tighten torque 20~23Nm

5.3.1.3 Add new oilAdd new oil according to the supplied procedure in the third section of chapter 3. About 6.9L5.3.1.4Check the oil leakageRunning the engine about 5 minutes, to preheat the unit, and check the leakage. 5.3.1.5After stopping the running 10 minutes, and then check the oil level of the oil bottom cover and supply to the upper limit.After the first maintenance, you should Replace the engine oil and filter element every 250 hours.5.3.2 Check after per 50 hours:5.3.2.1Drain out the fuel tank empty

Prepare a basin to keep the oil.

Screw down the plug, drain out the water and dirt empty.

Fit on the plug and tighten it, check oil leakage.

5.3.2.2Check the battery

Make sure the screw is tightened, if not, it will result in

severe accident.

The picture of Replace the oil filter element

5.3.2.1Drain out the fuel tank empty Prepare a basin to keep the oil.

Screw down the plug, drain out the water and dirt empty.

Fit on the plug and tighten it, check oil leakage.

5.3.2.2Check the batteryWhen check the electrical system, please break off the cathode grounding lead,

short circuit will produce fire, it may cause fire disaster.Be sure to provide adequate ventilation, it will produce hydrogen gas during

charging, the hydrogen gas will be burned by any fire source.Be careful of the electrolyte: do not let your skin and eyes touch the electrolyte,

it's acidity will hurt your skin and eyes. If it happened, clean your skin and eyes with plentiful water at once.

Check the level of the electrolyte.

If the level close to the lower limit, supply oil to the upper limit. If the electrolyte is over low, it will shorten the service life of the battery, even explode if the temperature is too high, the oil level decline quickly in summer, and you should check and supply the distilled water frequently.

When start the engine, if the crankshaft speed is lower than normal, and the

starting is failed, recharge the battery. If it still fails, you should replace the battery.5.3.2.3Clean the air cleaner

The air cleaner element is easy to be polluted by the dust, oil mist, steam. It will

increase the enter resistance, and the air will decrease, the engine will produce smoke. You should clean and check frequently, even Replace it.

When the engine work in the dusty place(stone pit, coal field, building field),

even clean the element more frequently, clean out the impurity.Takeout the element from the air cleaner shell, blow the inside with the

compress air, and blow out the dust. If the paper element is damaged, please change it.

Clean the grease in the air cleaner shell. Cover the intake with cloth; prevent

the rubbish drop into the intake pipe. Install the air cleaner, keep the element and rubber tube sealed, avoid air enter

into the cylinder not through the cleaner element.5.3.3Check for every 250 hours5.3.3.1Change the lubricant and oil fliter element, the method is same as 5.3.1.1 and 5.3.1.2. Replace it every 250 hours from the second time.5.3.3.2Check and clean the radiator chip

NOTE

DANGER

The dust and dirt adhered to the radiator chip will reduce the cooling capability,

make the engine over hot, according to the situation, you can clean it ahead,even

clean it every day.Blow out the dirt and dust with 196Kpa(2kgf/cm2)or less pressure compressed

air, if it is still dirty, you should use cleanser and water to wash thoroughly. Before using the compressed air, please wear the protection glass to protect

your eyes. Prevent the dust or float pieces hurt your eyes.Do not use the high-pressure tap and high-pressure air to wash by force, do

not use the brush to scrub, or the radiator chip will be damaged.

5.3.3.3Replace the air cleaner elementThe damaged air cleaner element will make the air into the cylinder not through

the air cleaner element, it will damage the valve, cylinder, piston, piston ring quickly.

If the element is plastered with dust, it will be hard to start the engine, the power will drop, and there will be black smoke.

Replace the element terminally, and clean the shell, it's benefit to the engine 5.3.4Check for every 500 hours5.3.4.1 Replace the fuel filter

Replace the diesel filter element terminally, before it choked by the greaseTurn off the switch of the fuel tank, disassemble the oil pipe, take off the

element, then clean the oil filter seatReplace a new diesel element, install the fuel filter, pay attention to the terminal

cover of the filter element is sealed, prevent the un-filtration fuel enter into the fuel injection pump.

Install in and out fuel pipe, turn on the switch of the fuel tank, advert drain out the air empty. Otherwise the diesel engine will be hard to start or stop running after starting.5.3.4.2Replace the cooling water:

After the cooling water is not hot, drain it, avoid the splash hot water scalding people.

If the cooling water or cooling liquid contain the rust and scale, the cooling effection will be depressed.

The cooling water should be replaced once a year at least. Drain the cooling water, and then add cleanly soft water.

5.3.4.3Check and adjust the valve clearance:

Make sure the valve is closed, before adjusting the gap, there will be clearance

Two methods to check or adjust

a. Single cylinder method: make sure the first cylinder locate in compression top

dead center then you can adjust the clearance between the intake and exhaust

valve(0.2~0.3)mm of 1-cylinder; turn the flywheel about 240 by

counterclockwise and then adjust clearance between the intake and exhaust

valve of 3-cylinder; turn the flywheel about 240 by counterclockwise last adjust

the 2-cylinder clearance. After all above, make sure put the adjusting bolt cap

together tight, or it will become loose, result in the unit can not work normally.

b.At twice method:

Put the 1-cylingder piston on compression top dead center, you can adjust the

following clearanace:

Rotate the flywheel about 240 by counterclockwise (rotary direction of the

engine), make the piston of 3-cylinder locate in compression top dead center

then adjust the other valve gap which is not adjusted

After all above, put the adjusting bolt cap together tight

5.3.4.4Check and adjust the injector

Check and adjust the injection pressure and quality of the spray on the test-bed,

the shape of spray as the following fig:

The 1-cylinder, 2-cylinder, 3-cylinder of the engine is marked from flywheel end to gear room, is different from the general method.There are top dead center reticule of each cylinder, you can look at it from dead center view port (Ö30) of flywheel cover, the top dead center reticule of 1-cylinder is marked on the belt wheel.

Cylinder order 1-cylinder 2-cylinder 3-cylinder

Adjustable valve Intake Exhaust Intake Exhaust

Cylinder order 1-cylinder 2-cylinder 3-cylinder

Adjustable valve Exhaust Intake Exhaust

Check the injection pressure and quality of the spray

If the injection pressure is incorrectly, you can screw down the injector shell, replace the different thickness adjusting gasket, make the pressure reach the right value 20 0.5 Mpa

The injection pressure is right, but the quality of the spray is bad. You can clean the injector orifice or replace the injector element

Put the injector into the cylinder cover, the gasket should be original, to make sure the unit's extended distance 2.2~2.3 mm If the warp of the extended distance is too large, the power, fuel consume, exhaust smoke of the diesel engine, will be affected greatly.

5.3.5Check for every 1000 hours:

5.3.5.1Check and adjust of injection timing

The adjustion need special tool, special

knowledge and skill, you should ask a respected

professional person do it.

Concrete steps

a. Remove all high-pressure oil pipes and bolt cap,

install a micrometer in the bolt hole. Press the

meter into 2 mm .see the fig.

b.Turn the crankshaft to put the 1-cylinder piston in

front of the top dead center about 30 ~40

adjust the micrometer to zero. Waver the belt wheel,

and check the reading of the micrometer. See the

fig

c.Turn the crankshaft as crankshaft rotation

direction: as clockwise rotation the belt wheel, and

align the oil supply scale mark 16 on belt

wheel with top dead center on gear room cover.

See the fig. The reading of the micrometer is

0.5mm. If not, the oil supply timing is wrong, need

adjust it.

d.The adjustion method is:

Loose the three fixing nut of injection pump and

the fixing bolt of injection pump bracket, adjust the

injection timing by changing the angle of injection

pump installation. See fig.

*If the reading is greater than 0.5mm, pull the oil

pump shell upside (away from engine). Reduce the

reading to the standard value; if the reading is

smaller than 0.5mm, push the oil pump shell upside

(near engine). Increase the reading to the standard

value.

Adjust the injection pressure

Screw up the fixing nut of injection pump and fixing bolt of injection pump

bracket after adjusting.

Remove the micrometer, install bolt cover.

Install high pressure oil pipe of 3 or 4 cylinder in turn.

5.3.5.2 Clean the scale and iron rust of cooling system

There will be much iron rust and scale in the radiator after running 1000 hours;

it will make the cooling water deterioration, reduce the radiating effection. You

should clean it at this time.

The work need special knowledge and skill, you should ask a respected

professional person do it.

5.3.6 Check after running 2000 hours:

5.3.6.1Check and replace the fuel, lubricating oil and cooling water and rubber

hose

Check rubber hose at time, if it is broken, please replace new one.

5.3.6.2Check and lap the seal band of inlet and exhaust valve.

The work need special knowledge and skill, you should ask a respected

professional person do it.

Check the sealability of valve, the subquality product of the valve, the width of

seal band and the clearance between the valve stem and valve guide

5.3.6.3Check the performance of the injection pump

The job needs oil pump test bed, adjust by professional man. Check oil supply

quantity of rated spot, the uniformity of each cylinder. Adjust the flexibility of each

part, the highest and lowest rotation speed limit and so on.

6. The engine troubleshooting

6.1 The alarm system fault

Item The reason of the malfunction Troubleshooting

4.The light of the air-in pressure and under voltage

1.The oil level is not enough2.The oil filter is jam

1.The cooling water level of radiator is too low

2.The core of the radiator was too dirty.

4.Fan, water pump drive "V" belt loose.

5.The malfunction of cooling water pump.

1.The malfunction of battery

2.The malfunction of line3.The malfunction of alternator

The element of air cleaner is so dirty

1. The alarm of lubricating oil

2. The light of cooling water temperature

3.Charging light

Add oilChange filter element

Add cooling water

Clean core of the radiator

Tighten or change

Service or change water pump

Check the electrolyte and chargeup anew or change batteryCheck service or changeService or change generator

Blow clear or change the element by compress air

3.Cooling water leakage, Coo-

ling water pipe is dirty.Check the part of water leakage,

clear or change the cooling water pipe

6.2 Start failed

The reason of the malfunction Troubleshooting

A. Malfunction of the supply system

1. Fuel tank was empty

2.Fuel system has air

3.The solenoid valve for oil off was not open

4.Fuel is incompetent

5.Air cleaner element is so dirty

6.The temperature of condition is too low

7.The filter element of fuel is jam

8.Oil supply time is untrue

9.Injection head is jam

10. Inlet and exhaust port is untrue

11. The compression of air cylinder is not good

a). Air valve is leakage

b).Air cylinder,piston,piston ring is heavy wear

12.The oil of injector pump is less

B. The malfunction of circuit

1.The battery power is not enough or tie-on loose

2.Starter engine is powerless, just idle running

3.Starter intermeshing is difficult

4.The rotation speed of starter is low

Add fuel

Drain air

Change the right spec oil

Change the new filter element

Use the air heater

Change the diesel filter element

Check or change oil nozzle parts

Check and adjust valve clearance

Service or lap the valve

Service by professional person

Put fuel injection pump on the experiment

table to service and adjust

Check the wire tie-in or the battery of electr-

olyte level and weight then charge

Service or change starter engine

The voltage drop of battery is larger or the

lead of battery is gracile in winter

Adjust the position between starter and flywheel gear

Check air cylinder compression pressure and the sta-

ndard value is 3.1Mpa, lowest value is 2.2Mpa

Check and adjust advance angle of fuel supply

Check the action of solenoid valve, service or change

6.3 The color of smoke is abnormal

The reason of malfunction Troubleshooting

A Black smoke

1.Diesel engine is over load

2.The air cleaner element is jam

3.Fuel is incompetent

4.Valve clearance is too large

5.Injection head is jam or leakage

6.The timing of oil supply is untrue

7.Valve is unsealed

8. Air cylinder, piston, piston ring is heavy

wear

Decrease load

Clear or change the air cleaner element

Use the fuel with right mark

Check and adjust the air valve clearance

Check sealed band, service and lap it

Change and service

B. Blue smoke 1.The oil level is too high

3. Oil seal of valve is disabled and the clear- ance of valve stem is too large4.Put the acclivitous face ring in reverse(the second ring)

Check the valve plate of breathing apparatus is sealed and the oil return hole is expedite

Drain oil of the fuel tank and water

Check injection pressure and the quality of spray

Check and adjust angle of advance of oil supply

2. The oil mist in breathing apparatus is too much

Check the oil level in the bottom with oil gage and drain oil

Change valve oil seal or service valve and pipe

Check and correct (the oil opening is underside)

C Whit smoke: the temperature is low in winter, whit smoke is natural when start-up, the temp-erature rise, the whit smoke will disappear.

2.Oil of injection is not atomization, fat liquor steam is drained

1. There is mix more water in fuel, vapour is drained

3. Injection advance angle is too later, oil gas is drained

4.Air cylinder, cylinder cover, head gasket is leak

Check the injection pressure and the quality of spraying

Check the reason of cooling water filter to the air cylinder

Check and adjust the injection advance angle

The reason of malfunction Troubleshooting

The reason of malfunction Troubleshooting

6.4Engine power is not enough

6.5 Running unstable

6.Oil level is small, oil supply is not enough

7.The oil of oil transfer pump is too small

8.The oil supply advance angle is wrong

10. Air valve clearance is wrong

11.The quality of oil is too bad

(1)Air valve leakage

(2)Cylinder head gasket leakage

(3)Cylinder piston piston ring is abrasion

(4)The mounting hole of oil injector leakage

1.The air cleaner element is so dirty air-inlet is not expedite

2.The element of fuel filter is dirty, oil-inlet is not expedite

3.The pipe of fuel is jam, oil supply is not expedite

4.The tie-in of oil suction pipe leakage and suction air

5.Timing spring is soft, rotation speed decline

9. The injection pressure and sprayer is tinpot

12.The breathing hole of the fuel tank cover is jam

13.Compression pressure of the cylinder is not enough

Clean and change the filter element

Clean and change the filter element

Check and clean or change the oil pipe

Check leakage and exhaust

Magnify the oil level

Check oil supply of oil transfer pump

Check and adjust

Check and adjust

Check and adjust

Use the fuel with right mark

Check and dredge

Change the concerned parts

Tighten or change the gasket of injector

Check the compression pressure of the cylinder (about 3.1Mpa)

Check and lap air valve or change air valve and air valve seat ring

Tighten the bolt of cylinder head or change head gasket

Check and adjust the rotation speed of engine

1.There will be air in fuel system

2.The drag rod of gasoline throttle is not flexible or clearance is too large 3.Timing is not flexible

5.The quality of injection pump spraying is so bad and oil dripping

Drain air, check the tie-in of oil suction tube leakageUse the oil pump experiment table

Use the oil pump experiment tableUse the oil pump experiment tableUse the injector experiment table

4.Injection pump is asymmetric for each cylinder

6.6 Engine is too hot

A. Water temperature is too high

3.Diesel engine is over load

5.Cooling water pipe is jam

6.Oil injection is too late

7.Burn is abnormal

8.The appearance of water tank is so dirty

10.Thermostat is broken

Add cooling water

Add water or drain air

Drop load

Tighten or change the belt

Check or change

Adjust the oil supply advance angle

Check the quality of the spraying

Clean the radiator core plate of water tank

Clean scale and rust with professional

Change the thermostat

Service or change water pump

Change

The reason of malfunction Troubleshooting

1.The cooling water is not enough in the water tank

2.There is air resistance in the cooling water tank

4.The belt of fan is too loose and rotation speed drop

9.The scaling of cooling system is very serious

11.Malfunction pump in of water pump is deviant

12.Water thermometer failure, reaction is wrong

The reason of malfunction Troubleshooting

B. Oil temperature is too high

1.Oil is too much or too little

2.The radiator is too dirty

3.The quality of oil is too bad

4.Blow-by loss of piston ring is too large

5.Cooling water temperature is too high

6.Diesel engine is over load

7.Oil temperature gauge failure

Check the oil level with oil dipstick

Clean the radiator

Use the right spec

Check cylinder, piston ring abrasion,

retaining ring, scuffing etc

Troubleshooting from above

Decrease load

Change

Diesel engine stop abruptly, run crankshaft first, if it is normal, check as following table, if it cannot run, the question is too bad, it must remove it to check

6.7 Stop abruptly

1.The fuel of fuel tank is use up

2.Oil pipe leakage, the oil road suction air

4.The solenoid valve of oil pump power

break down, cut off the fuel supply

7.Crankshaft can't running

a. Piston scuffing

c. Oil pump broken and can't oil pumping

d. Air valve is turn around and make piston,

cylinder jacket , cylinder head broken

Add fuelCheck leakage drain airChange fuel filter elementCheck circuit and solenoid valve

Change oil transfer pumpChange injection pumpDisconnect and check the reasonService with professional personService with professional personService with professional personService with professional person

b. The pressure of oil is too low or shortage oil

The reason of malfunction Troubleshooting

6.8 It has some abnormal voice when the engine running

1.Air valve clearance is too large, have clash

2. The clearance of piston and cylinder is too

large and slap

3.The clearance of main shaft tail and conn-

ecting rod bearing shell is too large and slap

4.The clearance of piston pin and small end

of connecting rod is too large

6.The clearance of crankshaft axial direction

is too large, crankshaft scurry .

7.Air valve bump piston

9.Injector is too early, clash crock

10.The parts of injector is broken

Check and adjust the clearance of air valve

Check and change the abrasion parts,

keep the spec clearance

Check crank journal, change crank shaft tile

Check and change connecting rod bushing

and piston pin

Change the piston and piston ring

Change the plummer block patch

Change gear

Check and adjust the oil supply timing

Clear or change the parts of nozzle tip

8.The clearance of the gearl is too large and slap

5.The clearance of piston and annular is too large

Check the air valve clearance , with gas phase and

the redundant clearance of cylinder compression